Method for manufacturing axle housings



Sept. 1942- A. c. SCOTT 2,296,743

METHOD FOR MANUFACTURING AXL E HOUSINGS Filed Sept. 9, 1940 Patented Sept. 22, 1942 OFFICE METHOD FOR MANUFACTURING AXLE HOUSINGS Albert Common Scott, Bush Hill, London,

England Application September 9, 1940, Serial No. 356,096 In Great Britain March 30, 1940 7 Claims.

This invention relates to a new method of manufacturing housings for the axles of automobiles and the like of the type in which the housing is formed with two tubular axle-receiving portions extending from a more or less central enlargement or banjo housing for receiving the usual differential gear.

The main object of the present invention is to provide a method of manufacturing such an axle housing from a flat sheet of metal as will involve a minimum of operations and will result in economy of material.

The invention is illustrated in the accompanying drawing, Figures 1-4 of which illustrate the various steps employed according to the invention;

Fig. 1 is a perspective view of a sheet of metal cut to the required size.

Fig. 21 is a perspective view of the sheet folded between its ends.

Fig. 3a is a like View showing the strip of Fig. 2 after pressing into semi-circular cross section.

Fig. 3 is a perspective view of the sheet of Fig. 30, after it has been folded longitudinally.

Fig. 4 is a perspective view of the housing after the axle housings have been formed.

A strip or blank I (Figure 1) of flat sheet metal is cut to the required size for forming a particular axle housing and the blank is pressed out or folded between its ends and generally at the central portion of the strip to form a channel 2 (Figure 2) which extends transversely across the width of the strip, the sides of the channel being sloped as indicated at 3; the blank thus formed is pressed out' longitudinally as shown in Figure 3 about its longitudinal centreline to form throughout the length of the blank a U in cross section, the base 4 of the U at the central portion 2 being, by reason of the preformed channel, below the base of the U of the end portions 5 at each side of the channel and the upper end of each limb 6 of the U of the central portion 2 being below the level of the upper end of the limb of the U of the other portions 5 at each side of the central portion.

This forming operation can be efiected in two stages in the first of which the longitudinal central portion of the strip is pressed into a die of the required semi-circular cross section, this stage forming the base of the U as is shown in Figure 3a; in the second stage the result of which is shown in Figure 3 the outer or edge portions of the strip shown in Figure 3a, are pressed up to form the side limbs 5, 6 of the U tangential to the base.

The base 4 of the U at this central portion is then slit longitudinally as indicated at l and the sides, formed by the limbs of the U at each side of the slit 1, are drawn apart transversely as shown in Figure 4 (i. e. the slit 1 is distended transversely) so as to cause each limb 6 of the U to form one half of a banjo wall 8, this operation also forming a flange 9 (at what corresponds to the base of the U) around the periphery of the walls. In the case shown, the banjo wall is circular but obviously any other shape may be formed. The limbs 5 of the U of the portions which extend at each side of the central portion are pressed over so that'the upper edges of the flanges of the U abut and their abutting edges are welded so as to form tubular axle receiving extensions III at each side of the central portion forming the banjo housing 8.

The operation in which the limbs of the U at each side of the central portion are pressed over and welded to form the axle-receiving extensions may be effected before or after the operation for forming the banjo housing is effected.

The unflanged end of the wall 8 provides a support to which a dust cover (not shown) can be welded.

It may here be pointed out that the formation of the transverse channel 2 before the longitudinal pressing is effected is of importance since the longitudinal pressing extends across the channel 2 to form puckers P to provide additional metal which is drawn upon in forming the banjo housing 8, and the sloping of the sides 3 of the channel enhances the pucker effect.

It follows that, as the additional metal required for the housing 8 is provided in this way, the original blank I can be of rectangular shape dimensioned to provide only the necessary metal for the formation of the tubular ends [0. 'As a rectangular blank can be used, economy in metal.

is effected since it is unnecessary to shape the blank, with the resulting waste of material.

In addition, the transverse channel 2 by causing the base of the U at the central portion to be below the base of the U of the end portions provides metal (i. e. the metal which joins the two bases referred to) from which, in combination with the lower ends of the limbs of the U of the central portion, the flange 9 can be formed.

What I claim is:

1. The method of forming an axle-housing from a flat sheet of metal which consists in cutting a metal blank to the required size and shape, in pressing out a portion of the strip between its ends to form a channel transverse of the strip, in pressing out the strip longitudinally about its longitudinal centre line to form throughout the length of the strip a U cross section, the pressing out extending across the transverse channel so that a pucker is formed in the metal, in slitting the base of the channel portion of the strip and drawing apart the parts of the channel at each side of the slit and pressing them so that each part forms one half of a banjo housing wall with a single flange, formedby the edges of the slit, and pressing over the limb portions of the U at each side of the channel portion so that the outer or upper edges of the sides of the U abut and welding the said edges together to form tubular axle-receiving portions at each side of the banjo. housing.

2. The method of forming an axle-housing. from a flat sheet of metal which consists in cutting a metal blank to the required size and shape, in pressing out a portion of the strip between its ends to form a channel transverse of the strip and with sloping: sides, in pressing out the strip longitudinally about its longitudinal centre line to form throughout the length of the strip a U cross section, the pressing. out, extending across the transverse channel so that. a pucker is formed in the metal, in slitting the base of. the channel portion of the strip and drawing apart the parts of the channel at each side ot the slit' and pressing them so that each part. forms one half of a, banjo housingv wall witha; single flange formed by the edges of the slit, and; pressing over the limb portions of the. U at each. side of the channel portion so that the outer free edges of the limbs of the U' abut, and. welding the said edges together to form tubular axle-receiving portions at each side of the banjo housing.

3. The method of forming an axle-housing from a flat sheet of metal which consists in cuttinga metalblank to the required size and shape, in pressing out a portion of the strip between its ends to form a channel transverse of the strip, in pressing out the strip. longitudinally about its longitudinal centre line to form throughout the length of the strip a U cross section, the pressing out extending across the transverse channel so. that a pucker is formed in the metal, in slitting the base. of the channel portion. of the strip, and. drawing apart the parts or the channel at each side of the slit. and pressing them. so. that each part. forms one half of a banjo housing wall with a single flange formed by the edges of the slit, and then pressing over the limb portions of the U at each side of the channel. portion so that the outer or upper edges of the. limbs abut and welding the said edges together to. form tubular axle-receiving portions at each side of the banjo housing.

4. The method. of forming an. axle housing from a flat sheet of metal which consists in cutting a metal blank to the required size and shape, in pressing out a portion of the strip between its ends to form a channel transverse of the strip and with sloping sides, in pressing out the strip longitudinally about its longitudinal centre line to-form throughout the length of the strip a U: cross section, the pressing out extending across the transverse channel so that a pucker is formed in the metal, in slitting the base of the channel portion of the strip. and

drawing apart the parts of the channel at each side of the slit and pressing them so that each part forms one half of a banjo housing wall with a single flange formed by the edges of the slit, and then pressing over the limb portions of the U at each side of the channel portion so that the outer or upper edges of the limbs abut and welding the said edges together to form tubular axle-receiving portions at each side of the banjo housing.

5. The method of forming an axle-housing from a flat sheet of metal which consists in cutting a metal blank to the required size and shape, in pressing out a portion of the strip between its ends to form a channel transverse of the strip, in pressing out the strip longitudinally about its longitudinal centre line to form throughout the length of the strip a U cross section, the pressing out extending across the transverse channel so that a pucker is formed in the metal, in slitting the base of the channel portion of the strip, in pressing over the limb portions of the U at each side of the said channel and weldingv their abutting edges together. to form tubular axle receiving, portions at. each side of the channel, and then drawingv apart. the parts of the channel at each side of theslit and pressing them so that each of said parts forms one half of a banjo housing with the tubular axle receiving portions. extending at each side of the said housing.

6. The method of forming an axle housing from a flat sheet of metal which consists. in transversely pressing-out an intermediate part of a metal blank, in pressing out the strip. longitudinally throughout its length, including the intermediate transversely pressed out part so as to form the strip into a U cross section throughout its length with the U at the intermediate part below the U at the end part, in slitting: the base of the. U at the intermediate part, drawing apart the parts of the U at each side of the slit to form a banjo housing with. a single flange formed from the metal at the lower ends of the U of the intermediate part and from the metal, joining the base of the U of the lower interme diate part with the base of the U. of the end parts, and pressing over the limb portions of the U of the end parts so that the outer edges of these portions abut to form tubular axle-receiving portions at each side of the banjo housing.

7. The method of forming an axle housing from a flat sheet of metal which includes transversely pressing out the strip at an intermediate part and longitudinally pressing out the strip to form a single uniform U cross section throughout. the length of the strip, the. two pressings providing puckers, in slitting centrally along the base of the single longitudinal U at the intermediate part and drawing apart the parts of the metal adjacent the slit and pressing them so that the two limbs of. the U form respectively the two half walls of a banjo housing the metal of the puckers being drawn during this housingforming step, and pressing over the limb portions' of; the single longitudinal U of the end parts so that the outer edges of these portions abut to form tubular axle-receiving portions at either side of the banjo housing.

ALBERT COMMON SCOTT; 

